Panel cutter with efficient and effective clamping system

ABSTRACT

A panel cutter has a clamping mechanism positioned adjacent to the cutting path to hold the panel material in position during the cutting process. The clamping mechanism includes a clamping bar which is removably coupled to a pair of lever mechanisms which are rotatably coupled to the framework of the panel cutter. An actuator bar having cams at both ends is also coupled to the framework and position adjacent to the lever arms, wherein movement of the actuator bar causes movement of the lever arms. Based upon the configuration and positioning of these components, movement of the lever arms causes the clamping bar to move between a locked position and an unlocked position.

BACKGROUND

Mechanisms that can effectively and efficiently cut large panels areused in many different applications, including lumber yards, retailstores selling lumber and/or building materials, cabinet shops, signfabricators, and other woodworking shops. One example of a panel saw isshown and disclosed in U.S. Pat. No. 4,802,399 “PANEL SAW APPARATUS”,issued on Feb. 7, 1989 to Olson. As shown in the Olson patent, thisapparatus can easily make large cuts in a very controlled manner. Thatsaid, the device of Olson is primarily directed toward cutting plywoodor other hard panel materials.

SUMMARY OF THE INVENTION

To provide a cutting apparatus that efficiently cuts panel materials, acutting mechanism and related clamping system are configured to uniquelycooperate with one another. Generally speaking, the vertical panelcutter includes a support framework designed to support and orient apanel of material to be cut in a substantially vertical manner. Thecutting mechanism is carried on a carriage, which is guided along apredetermined cutting path, with the carriage being slidably coupled toa pair of guide rails. In an effort to provide more efficient andeffective cutting, the related clamping system includes a clamping barwhich extends adjacent to and parallel with the cutting path, and whichis movable between a locked or holding position and an unlocked or openposition. The clamping bar is supported at an upper and lower end byrespective lever mechanisms, which accommodate the movement between thetwo stated positions. Each lever mechanism is rotatably attached to theframework of the panel cutter at an appropriate position. An actuatorarm is also attached to the framework and carries a pair of cams oneither end which also cooperate with the lever mechanism. In operation,the actuator arm is rotated, thus causing interaction between the camsand the lever mechanism. Due to the orientation and configuration ofthese components, the lever mechanism will then move the clamp barbetween the two desired positions. In this manner, clamping/holding ofthe panel material can be easily accomplished by the simple movement ofthe lever and related rotation of the actuator arm.

BRIEF DESCRIPTION OF THE DRAWINGS

The further details and advantages of the preferred embodiments can beseen from the following description of the preferred embodiments inconjunction with the drawing, in which:

FIG. 1 is a perspective view of the panel cutting device with theimproved holding mechanism;

FIG. 2 is a back view of the top end of the holding bar mechanism;

FIG. 3 is a back view of the bottom end of the holding bar mechanism;

FIG. 4 is a view of the top of the holding bar mechanism looking fromthe bottom;

FIG. 5 is a view of the bottom of the holding bar mechanism looking fromthe top; and

FIG. 6 is a view of the bottom of the holding bar mechanism looking fromthe top with the holding bar mechanism in the locked position.

DESCRIPTION

As illustrated in FIGS. 1-6, and generally discussed below, a newlydesigned panel saw clamping mechanism is presented which is particularlyuseful in the sign industry. That said, the same mechanism could beapplied to other systems and applications. As will be appreciated fromthe details outlined below, certain elements of the panel saw apparatusare not shown in the attached figure, so that an improved clampingmechanism can be better illustrated.

As generally illustrated in FIG. 1, the clamping mechanism 40 isattached to a frame 20 of a panel saw system 10 at a location adjacent asaw carriage 30. Those familiar with panel saws will recognize that asaw (not show) is often carried by saw carriage 30, thus allowingcontrolled movement. In the illustrated embodiment, the saw carriage 30will be carried/guided by a set of rails 24 so it can easily move up anddown. In this embodiment, a panel (e.g. plastic panel, plywood, orsimilar type of material configured as a relatively flat panel) issupported on the panel saw, so that desired cuts can be made by simplymoving carriage 30 (and attached saw) along rails 24. Although referenceis made to a saw, a cutting knife or blade could also be used, dependingon the materials involved. In certain alternatives, this panel saw couldbe used in the cutting of plastic panels, plexiglass, foam board, etc.As will be appreciated, the clamping of these “softer” or “moreflexible” materials provides significant advantages and helps to moreefficiently carry out cutting operations.

To improve operation of the panel saw or cutting knife, clampingmechanism 40 is added so a panel can be securely held in position duringcutting operations. The clamping mechanism 40 includes an actuator arm50 which is rotatably and removably attached to the frame 20 via abracket 46. A cam 52 is attached to each end of the actuator arm 50. Alever or handle mechanism 54 which is configured to allow rotation ofactuator arm 50. Generally, a clamp bar 82 is attached to levermechanism 72 which carries out a clamping function. All of thesecomponents are positioned and configured so that clamp bar 82 will bepositioned close to or immediately adjacent to the cutting zone (i.e.the path of the cutting blade). Again, the path of cutting blade iscontrolled by the configuration of carriage 30 and guide rails 24. Inaddition, handle 54 is accessible by a user, but is positioned outsideof the cutting area, thus providing an additional level of safety.Further, all components are designed so that the clamp bar 82 is easilyremovable so that alternative cutting operations can be completed andpotential interference is avoided.

In use, handle 54 allows a user to rotate actuator arm 50, which willalso cause rotation of cams 52. The cams 52 are specifically designedand fabricated to interact with lever mechanisms 62, 72, and thus causeclamp bar 82 to move into a locked position when desired. Similarly,clamp bar 82 can be moved to the unlocked position by rotating theactuator bar 50 in the opposite direction. Referring now to FIGS. 4-6,details of clamping operations can be better seen. FIGS. 4 and 5 showthe top portion and bottom portion, respectively, of the clampingsystem. Again, a single actuator arm 50 is coupled between these twosystems. In essence, the top portion (illustrated in FIG. 4) is a mirrorimage of the bottom portion (illustrated in FIG. 5). As can be seen,cams 52 are both attached to opposite ends of actuator arm 50. Bottomlever mechanism 72 is attached to framework bracket 46 at a pivot point73. Similarly, top lever mechanism 62 is attached to framework bracket47 at a pivot point 63.

As generally discussed above, actuator arm 50 is rotatably coupled toframework brackets 46 and 47 and can be operated using handle 54.Rotation of actuator arm 50 causes related movement of cams 52, whichare permanently attached to actuator arm 50. As shown, cams 52 have anirregular shape, thus causing forces to be applied to top levermechanism 62 and bottom lever mechanism 72 when actuator arm is rotated.In both FIGS. 4 and 5, clamp bar 82 is shown in the open or unlocked orunclamped position. By contrast, referring to FIG. 6, actuator arm 50and cams 52 have been rotated causing lever mechanism 72 to rotate. Thismovement of lever mechanism 72 causes clamp bar 82 to move into theclosed or locked or clamped position. Again, this closed or lockedposition is best illustrated in FIG. 6.

To provide efficiency, clamp bar 82 is designed to clamp the full lengthof the material being cut in a uniform manner. Although not required, itis helpful if this clamping can occur immediately adjacent the cuttingzone, to make cutting operations more efficient. In one example, theclamp bar 82 is positioned within inches of the cutting zone andparallel to the cutting path.

In addition to the details above, clamp mechanism 40 was designed foreasy removal, thus allowing the machine to perform other cuttingapplications which may not benefit from the clamp, including bothhorizontal and vertical cutting operations. As an example, the cuttingof plywood, rigid plastic panels, or thicker material may not requirethe use of the clamp to obtain efficient cuts. In the disclosedembodiments, the removal and/or reinstallation of the clamp can be donein a matter of seconds. Referring to FIGS. 2 & 3, machined blocks 86, 96on each end of the clamp bar 82 are slotted to except a pin 84, 94 thatis connected to the main structure. These machine blocks include apressure spring 89, 99 that can be pushed in to exert pressure on oneend, which allows the other end of the clamp bar 82 to be removed.

As discussed above, the clamping mechanism described in the identifiedembodiment makes use of a rotatable actuator arm having cams 52 attachedto each end which interact with lever mechanisms 62, 72 and to causemovement. With clamp bar 82 attached to an end of lever mechanisms 62,72, this creates the desired movement between the closed or lockedposition, and the open or unlocked position. Those skilled in the artrecognized that alternative schemes could be utilized. For example,gears, levers or other movement mechanism could be possible. In such analternative mechanism, a lever could be used to create straight linemovement of components, which could then be translated into movement ofa related clamp bar between an unlocked position and a locked position.

Various embodiments of the invention have been described above forpurposes of illustrating the details thereof and to enable one ofordinary skill in the art to make and use the invention. The details andfeatures of the disclosed embodiment[s] are not intended to be limiting,as many variations and modifications will be readily apparent to thoseof skill in the art. Accordingly, the scope of the present disclosure isintended to be interpreted broadly and to include all variations andmodifications coming within the scope and spirit of the appended claimsand their legal equivalents.

1. A clamping mechanism for use on a panel cutting system to efficientlyand effectively hold a panel to be cut using a movable cutting blade,comprising: an actuator arm having a handle attached thereto, whereinthe handle is accessible by a user and is located a distance away from acutting zone, and wherein the actuator arm is attached to a frameportion of the panel saw via a bracket, and movement of the handlecauses movement of the actuator arm; a lever mechanism coupled to theframe of the panel saw and positioned adjacent the actuator arm, whereinmovement of the actuator arm causes movement of the lever mechanism; anda clamp arm coupled to the lever mechanism to provide clamping force tothe panel, wherein movement of the lever arm causes the clamp arm to bemoved into contact with the entire panel at a location near the cuttingblade.
 2. The clamping mechanism of claim 1 wherein the clampingmechanism can be easily removed from the frame.
 3. The clampingmechanism of claim 2 wherein the clamping arm is coupled to the levermechanism using a spring loaded pin.
 4. The clamping mechanism of claim1 wherein the actuator arm is rotatably coupled to the panel cuttingsystem and includes a cam attached thereto, and wherein the caminteracts with the lever mechanism to cause the movement of the levermechanism.
 5. The clamping mechanism of claim 1 wherein the movablecutting blade follows a predetermined cutting path, and wherein theclamp arm is positioned adjacent to and parallel with the cutting path.6. The clamping mechanism of claim 5 wherein the clamp arm is within twoinches from the cutting path when engaged with the panel material.
 7. Apanel cutting saw configured to support and hold panel material whilebeing cut, the panel cutting saw comprising: a support framework havinga support structure and a support rail configured to hold the panelmaterial during cutting operations; a cutting carriage supporting acutting blade and carried by a guide rail system which allows thecutting blade to follow a predetermined cutting path; and a panelclamping mechanism for holding the panel material on the supportframework in a position adjacent the support structure and support rail,the clamping mechanism comprising: an actuator arm rotatable coupled tothe support framework, the actuator arm having a first cam at a bottomend and a second cam at a top end; a first lever mechanism coupled to alower portion of the framework and positioned adjacent to the first cam,wherein rotation of the first cam creates movement of the first levermechanism; a second lever mechanism coupled to an upper portion of theframework and positioned adjacent to the second cam, wherein rotation ofthe second cam creates movement of the second lever mechanism; and aclamping bar coupled to the first lever mechanism and the second levermechanism; wherein movement of the first and second lever mechanismcauses related movement of the clamping bar.
 8. The panel cutting saw ofclaim 7 wherein the clamping mechanism can be easily removed from theframe.
 9. The panel cutting saw of claim 8 wherein the clamping arm iscoupled to the first lever mechanism and the second lever mechanismusing a pair of spring loaded pins.
 10. The panel cutting saw of claim 7wherein the clamp arm is within two inches from the cutting path whenengaged with the panel material.
 11. The panel cutting saw of claim 7wherein the clamping bar is movable between a locked position to holdthe panel material to be cut, and an unlock position wherein theclamping bar is clear from the panel material to be cut.
 12. The panelcutting saw of claim 7 wherein the cutting blade is a straight blade.13. The panel cutting saw of claim 7 wherein the cutting blade is apowered cutting blade